Ana$White$Workbenchfor$Ryobi$ Page 1 22eff5c75290b0e498bfcc-cdb2fd2cc8e016557784fa363a27… · · 2016-02-05Microsoft Word - ana white workbench ryobi benchtop tool update.docx

Ana White Workbench for Ryobi Page 1 of 22

Tools

• Miter Saw • Drill with drill bits • Pneumatic Stapler • Tape Measure • Square • Table Saw • Clamps

Shopping List

• 4 Sheets of 3/4” plywood • 2 sheets of 1/4" plywood • 8 – 3” casters with brakes • 3/4” screws for attaching caster wheels • 11 – 2x4 @ 8 feet long • 8 – 1x2 @ 8 feet long • 3” self tapping wood screws • 2” and 1-‐1/4” 18 gauge staples • 4 handles for carts


Workbench Cut List

• 6 – 2x4 @ 49” • 4 – 2x4 @ 28” • 8 – 2x4 @ 39-‐1/2” • 2 – 1/4” plywood @ 39-‐1/2” x 31” (see plywood cutting diagrams) • 2 – 3/4” plywood @ 52-‐1/4” x 31” (see plywood cutting diagrams) • 4 – 2x4 @ 29-‐1/2” • 2 – 2x4 @ width of saw (shown at 24”) • 2 – 3/4” plywood @ width of saw x 31” (shown at 24”)

Cart Cut List

• 2 –3/4” plywood @ 48” x 30” (see plywood cutting diagrams) • 4 – 3/4” plywood @ 8-‐1/4” x 30” (cut from scraps, see plywood cutting diagrams) • 24 – 1x2 @ 28” • 8 – 3/4” plywood @ 8-‐1/4” x 28” (cut from scraps, see plywood cutting diagrams) • 4 – 1/4” plywood @ 30” x 28-‐3/4” • 4 – 3/4” plywood @ 48” x 29-‐1/2” (see plywood cutting diagrams)



Workbench Step 1: Build Workbench Frames

Attach using 3” wood screws and glue at corners. Check for square and adjust as needed.


Workbench Step 2: Legs

Attach legs to frame with four 3” screws and glue. Check to make sure legs are installed square with the frame.


Workbench Step 3: Bottom Support

Attach bottom support to back legs of bench, 4” from bottom of legs. Use 3” wood screws and glue.


Workbench Step 4: Plywood Side

Use glue and 1-‐1/4” staples to attach ¼” plywood to side of workbench. Remember to plywood the outsides of the bench as shown in below diagram:


Workbench Step 5: Workbench Top

Attach workbench top to frame with 2” staples and wood glue.


Miter Saw Shelf Step 1: Cleats

Measure the height of your miter saw deck. Add 3/4” to this measurement. Attach top cleats to sides of workbenches this measurement down from top of workbench. Cleats are flush to back, 1-‐1/2” less on front side. Use 3” screws.

Attach bottom shelf cleats with 4” space underneath.


Miter Saw Shelf Step 2: Front Trim

Attach front trim to workbench legs and cleats with 3” screws.


Miter Saw Shelf Step 3: Shelving

Place plywood shelving on cleats and attach with 1-‐1/4” staples and glue.


Cart Step 1: Caster Wheel Height

Measure the overall height of your caster wheels. Maximum clearance under workbench is 36” but some space should be left to allow cart to slide in. Cut list as shown is for casters with 3-‐3/4” clearance – adjust your cuts if your caster wheels are different heights.


Cart Step 2: Cart Frame

Use 2” screws to attach cart front to cart shelf end with 1x2s. Build two of the cart frames.


Cart Step 3: Shelves

Attach remaining 1x2s to shelves with 1-‐1/4” staples from underside. Then attach shelves inside cart frames with 2” screws or staples and glue.

TIP: Cut two 9” blocks of wood and use as spacers when placing shelves.

NOTE: Shelves can be placed at any height – customize to fit your needs and toolset.


Cart Step 4: Shelf Backs

Attach backs to shelves with 1-‐1/4” staples and glue.


Cart Step 5: Top and Bottom

Attach top and bottom to cart frame with 2” staples and glue.


Cart Step 6: Caster Wheels

Install caster wheels on bottom of carts with ¾” screws.


OPTIONAL BENCH TOP TOOLS

Step 1: Benchtop Cutout

Use a circular saw or jigsaw to carefully cut out the top of the workbench cart, following back of shelves and cutting to depth needed for your bench top tools. Make sure you leave about 2” extra for adding the cleat in step 3.


Step 2: Bench Top Cleats

Cut 1x2 cleats 1-‐1/2” less than the opening depth. Screw to the insides of the workbench cart, so the 1x2 top is flush with the bottom edge of the plywood workbench top.


Step 3: Benchtop Tool Shelf

Attach a 1x2 cleat flat to 3/4” thick plywood cut to match the opening of the benchtop. Test fit and adjust if necessary.


Step 4: Bench Top Tool

Attach Bench top tool to the removeable tabletop piece as recommended by the tool’s guide. Only lighter tools should be hung upside down. Additional cleats can be added inside cart for storing more benchtop tools.


Step 5: Tablesaw Modification

Repeat steps as directed for benchtop tools, except custom cut tabletop out to fit your tablesaw, leaving enough room for the tablesaw fence, guides and accessories to freely move. Use cleats and ¾” plywood to create a shelf for the tablesaw. When installation is complete, the tablesaw deck should be slightly higher than the tabletop itself. Secure tabletop to shelf.

Ana$White$Workbenchfor$Ryobi$ Page 1 22eff5c75290b0e498bfcc-cdb2fd2cc8e016557784fa363a27… · · 2016-02-05Microsoft Word - ana white workbench ryobi benchtop tool update.docx

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